Blow Molding & Plastics Discipline

Since 1999

Blow Molding Help and Associates

Successful Projects designed and lead by BMHA team members

Design Engineering changes to increase throughput on a 36” Crown Hoe litho press system, which typically was limited to 63 passes per minute. Upon completion the line was capable of speeds up to 85 passes per minute

Designed Quick Change system utilizing adhesive backed measuring tape to dial in pre-set adjustments.

Crown Hoe 36” Upgrade Modification

Lean Automation of Case Erector

Projects underway and completed

PET Blow Molding Change time reduced from 12.5 hours down to 2 hours 11 minutes in two sessions.

SMED Implementation Shows 84% improvement in C/O Downtime

Typical SMED Results from Organized Systems

PACKAGING SMEAD TEAM

THE ROAD TO SET-UP REDUCTION

 

FACILITATE TEAM MEETINGS

TRACK CHANGEOVER TIMES

IMPLEMENT NEW SET-UP PROCEDURES

IMPLEMENT QUICK CHANGE IDEAS SUBMITTED FROM TEAM

SET NEW TEAM GOALS

OVERSEE CHANGEOVERS

 

RESOURSE TEAM

ENSURE ALL BOTTLES AND CORRUGATION IS PACKED OUT BEFORE DOWNSTREAM CHANGEOVER BEGINS

ENSURE STAGING OF NEW CORRUGATION FOR NEXT RUN

ENSURE PROPER SKID TAGS ARE PROVIDED

SUPPLY SET UP BOTTLES FOR CHANGE TEAM TO SET UP ALPS LEAK DETECTOR AND PEARSON PACKER

OVERSEE TOOLING CHANGES DOWNSTREAM

PROVIDE PERSONNEL TO BUILD A BOX BANK PRIOR TO START-UP

DEBUG DOWNSTREAM BEFORE RELEASE OF  1ST. SHIFT  PACKOUT TEAM MEMBERS

 

SIDEL & PROCESS TEAM LEADER

INSPECT MOLDS SETS PRIOR TO CHANGEOVERS

PROVIDE CORRECT PROCESS SET-UP SHEETS

PROVIDE OVEN CONFIGURATION SET-UP INFORMATION

PROVIDE PROCESS SUPPORT

COORDINATE BOTTLE SPECIFICATIONS POSTINGS WITH QUALITY RESOURCE

PRODUCTION SUPERVISORS

VERIFY PREFORM SOURCE AND INVENTORIES

ENSURE PRE-STAGING OF  PREFORM FOR NEXT RUN

PROVIDE MECHANIC SUPPORT WHEN NEEDED

BMT’S PACKOUT TEAM

COMMUNICATE PRODUCTION SCHEDULE AND CUSTOMER  REQUIREMENTS TO TEAM

VERIFY CORRUGATE AVAILABILITY AND DELIVERY TIMES

PROVIDE PART NUMBER TAGS FOR BOTTLE PRODUCTION

 

QUALITY SOURCE

Verify section weight cutter set up

Ensure posting of bottle specifications on line

Provide up to date bottle section weights

Provide data reflecting bottle performance of last run of new product

Ensure all new products adhere to GPC-830

Facilitate timely hot  fills

 

CHANGEOVER TEAM

CONTRIBUTE SET-UP REDUCTION IDEA’S TO THE TEAM

RECORD STEP 22 CHANGE OVER TIMES

WORK AS TEAM TO REACH SIX HOUR CHANGE OVER GOAL

CHANGE OVER

PRODUCT LINES

PROMOTE SAFETY

TEAM GOALS

Understand the benefits for set-up reduction.

TEAM GOALS

2. Formulate a procedure to analyze the steps taken during a mold change.

3. Document times of each step of the mold change.

4. Analyze the mold change step times and make recommendations to reduce each part of the process.

5. Compile all recommendation and submit to SMEAD team for discussion.

6. Format a change-over procedure using new step recommendations.

7. Perform change-over using new procedure and compare step times to old procedures for any actual setup reductions.

8. Assess the results.

9. Present results to team.

FIRST STEP

VIDEO TAPE THE CHANGE OVER

VIEW TAPE AND DOCUMENT

ORGANIZE INTO STEPS

FORMAT INTO WORK SHEET

USE FOR NEXT CHANGE

FIRST SET-UP STEP BREAKDOWN

PROCESS 29%                                                                        

HOT FILLS 7%                                                                       

PREPARATION 14%                                                                                                              

LINE CHANGE 49%

ASSESS THE RESULTS

BRING DATA BACK TO TEAM

ASSESS THE RESULTS

DISCUSS WAYS FOR IMPROVEMENT

DOCUMENT SUGGESTIONS

IMPLEMENT FOR NEXT PRODUCT CHANGE

IMPLEMENTATION

IMPLEMENT 22 STEP WORK SHEET INTO PROCEDURE

CONTINUAL IMPROVEMENT

SET NEW GOALS

REWARD ACHIEVEMENTS

 

Note:

2000 average change over on the SBO-18 /II was 12.36 Hr’s

4-16-2001 After SMED Team implemented, The team was able to reduce the change over average to 2.11 Hr’s This is an astonishing 83 percent improvement. Team members, let’s plan a recognition event for all the members of your respective teams.